Method for operating a shearing and compacting press and shearing and compacting press

ABSTRACT

The invention relates to a method and to a shearing and compacting press for the production of pressed parts, preferably packages ( 20 ) from waste material, especially scrap and sheet clippings. The material used is pre-compacted in a first compacting step. In a second compacting step, the material, which has been pre-compacted to the width of the package, is subjected to intermediate compacting until the height of the package ( 20 ) is reached. In a third compacting step, final compacting of the material to the final width or length of the package ( 20 ) is carried out. According to the invention, the material is pre-compacted with a continuos force and optionally sheared until the compressor ( 3.1 ) reaches its final position. The compressor ( 3.2 ) is securely adjusted and guided to its end position on a parallel plane. Subsequently, the compressor ( 3.3 ) is guided in a position in which the compressor ( 3.1 ) releases the opening of the package chamber ( 2.3 ) when the compressor ( 3.1 ) is driven back. Finally, the compressor ( 3.1, 3.2, 3.3 ) is subjected to a pressure that is lower than the maximum pressure available in the compressors ( 3.1, 3.2, 3.3 ) at the beginning of the working and return strokes. The compressor ( 3.1 ) is subjected to maximum pressure for shearing and/or the compressors ( 3.2, 3.3 ) are supplied with maximum pressure to end pressing. The invention is also characterized in that the pressing pressure for the compressors ( 3.1, 3.2, 3.3 ) is gradually controlled depending on the degree of compression or the corresponding length.

FIELD OF TECHNOLOGY

The invention relates to a method for operating a shearing andcompacting press, as well as a shearing and compacting press forproducing pressed parts, in particular packages of scrap metal and sheetclippings.

STATE OF THE PRESENT TECHNOLOGY

Shearing and compacting presses are known which consists essentially ofa filling chamber with a shearing edge, a compressor with a shearingknife guided horizontally therein, a pressing chamber arrangedperpendicular thereto, and a compressor guided in the pressing chamber,as well as a package chamber which is oriented horizontally andperpendicular to the filling chamber and has a horizontally guidedcompressor.

In particular embodiments, the filling chamber and the pressing chamberterminate in a common space, which is the above-reference packagechamber that receives the package-shaped pressed part. The walls of thefilling chamber, the pressing chamber and the package chamber form thehousing of the shearing and compacting press. The package chamber has anopening for the door which can be moved horizontally, with the ejectedpressed part passing through the door. The compressors and the door areoperated by hydraulic pistons/cylinders connected with a hydraulic drivesystem.

For producing pressed parts, preferably packages, from waste material,in particular from scrap metal and sheet metal clippings, theconventional shearing and compacting presses perform

a first compacting step for pre-compacting the supplied material to thewidth of the package using a compressor which is horizontally guided ina filling chamber, wherein any material projecting over the compressorcan be cut at a shearing edge using a shearing knife located on thecompressor,

a subsequent second compacting step for intermediate compacting of thematerial that was previously pre-compacted to the width of the package,to the height of the package using a compressor guided in a pressurechamber in a direction perpendicular to the filling chamber,

a subsequent third compacting step for final compacting of the materialto the final density and/or length of the package using a compressorwhich is guided in the package chamber horizontally and in a directionperpendicular to the filling chamber, wherein after attaining the finalthickness or length, the finished package is ejected from the packagechamber through the door, and

finally controlling the compacting steps through a drive systemproducing a hydraulic pressure.

The basic principle of the method and the construction of the apparatushave met with success in practical applications. However, it would bedesirable to implement additional functional improvements and optimizethe design.

SUMMARY OF THE INVENTION

It is the object of the invention to provide a method for operating ashearing and compacting press of the aforedescribed type, wherein theshearing and compacting press achieves a higher utilization rate inparticular through cooperation of the compacting steps. The shearing andcompacting press should be able to utilize the modified and improvedaforedescribed components and subassemblies.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a partially cut-open perspective view of a shearing andcompacting press,

FIGS. 2a and b show top views of FIG. 1 with different arrangements ofthe hydraulic drive system,

FIG. 3 shows schematically the functional unit door,

FIG. 4 shows schematically the arrangement of the forces in the regionof the functional unit door,

FIG. 5 is a view from the left side of the shearing and compacting pressof FIG. 1,

FIGS. 6a and b are two schematic illustrations depicting the cooperationof the first and third compressor,

FIG. 7 is a perspective view of the compact drive unit alone,

FIGS. 8a and b show two embodiments of a metering device of the cut-openfilling chamber of the shearing and compacting press, and

FIGS. 9a and b show the cut-open filling chamber with two differentpositions of the pressing cover.

BEST MODE FOR CARRYING OUT THE INVENTION

First, the basic construction of the invention will be described.

Referring now to FIG. 1, the housing of a shearing and compacting press1 consists of a filling chamber 2.1, a pressing chamber 2.2 and apackage chamber 2.3, as well as a compressor 3.1 driven by apiston/cylinder 6.1 and having limit stops 7.1, a compressor 3.2 drivenby a piston/cylinder 6.2 and having limit stops 7.2 (FIG. 5), and acompressor 3.3 (FIG. 2a). The compressor 3.2 has a shearing edge thatcooperates with a shearing knife 4.2. A door 5.1 connected with apiston/cylinder 6.4 is guided in a door casing 5.2 with a lateral guide5.3 (FIG. 4), for horizontal movement in a lower guide 5.4 (FIG. 3). Thedoor casing 5.2 is secured to the housing portion of the package chamber2.3 by tension rods 10, with the tension rods 10 simultaneouslyabsorbing the pressure against the door 5.1 which the piston/cylinder6.3 applies via the compressor 3.3 on the pressed part 20.

FIGS. 2a) and b) depict different possible arrangements for installingthe hydraulic drive system 9.1 of the shearing and compacting press 1.The hydraulic drive system 9.1 includes the control block 9.2, ahydraulic reservoir 13 (FIG. 7), an oil pan 14 (FIG. 7 ) and switchblock 16, which together form a compact, preassembled subassembly 15.

The synergistic operation of the compressor 3.1 and 3.3 illustrated inFIGS. 6a) and b) creates a respective space which is protected from thepotential incursion of falling material to be pressed. FIGS. 8a) and b)show two modifications of two different metering devices 12 for feedingthe material to be processed. FIGS. 9a) and b) show to positions of apressing cover 11 for the filling chamber 2.1.

The method according to the invention for operating the shearing andcompacting press 1 includes the following basic sequence of steps and/orflows and interactions, after the filling chamber 2.1 has been filledwith the material to be pressed by one of the metering devices 12:

pre-compacting with a continuously applied force and optionally shearingthe material by guiding the compressor 3.1 non-adjustably on a parallelplane, thereby eliminating the tilting moment of the compressor 3.1produced by the shearing operation, until the end position in the firstcompacting step,

in the subsequent second compacting step, non-adjustably guiding thecompressor 3.2 in a parallel plane towards the end position of theintermediate compacting operation,

guiding the compressor 3.3 in the third compacting step, wherein thecompressor 3.1 is already in a position unblocking the operation of thepackage chamber 2.3 when the compressor 3.3 is returned to a position inwhich falling material does not interfere with the stroke motion of thecompressor 3.3,

applying pressure to the respective compressors (3.1, 3.2, 3.3) which

for the compressors 3.1, 3.2, 3.3 is below the available maximumpressure at the beginning of the working strokes and the return strokes,and

for the compressor 3.1 for the shearing operation and/or for thecompressors 3.2, 3.3 provides the maximum attainable pressure at therespective end of the pressing operation, and

an automatic control of the pressing pressure for the compressors 3.1,3.2, 3.3 adapted to the respective degree of compression and therespective length, for the purpose of reliably controlling the functionsof the compression process until completion of the final pressing step.

The return strokes of the compressors 3.1, 3.3 are coupled, wherein thecompressor 3.3 travels an initial portion of the path by itself and theremaining portion of the path together with the compressor 3.1.

The movements of the compressors 3.1, 3.3 are matched to one another, inthat the compressor 3.1 is returned behind the shearing edge 4.1 inorder to be able to again feed material into the filling chamber 2.1,only after the compressor 3.3 is on the return stroke from the packagechamber 2.3. This arrangement prevents material from entering the spacebetween the pressing plate of the compressor 3.3.

The door 5.1 is closed simultaneously with the return stroke of thecompressor 3.3 through hydraulic separation or opened simultaneouslywith the return stroke of the compressor 3.2 through hydraulicseparation.

All these process flows use a measurement system that monitors themovements of the compressors 3.1, 3.2, 3.3 and the door 5.1 as well asthe package size, and supplies signals for changing the process flow,such as material feed, package density, applying pressure to thepistons/cylinders 6.1, 6.2, 6.3, 6.4, oil level (leakage).

For this purpose, a control device is employed which drives thecompressors 3.1, 3.2, 3.3 and the door 5.1, wherein the control devicethroughout the initial and intermediate compression steps and until thefinal compression and ejection of the package 20, records and processesat least one of the following functions before the material is supplied,and optionally intervenes in the process flow:

changing the material feed depending on the material required for thecompression process,

changing the pressing pressure of at least one of the compressors 3.1,3.2, 3.3 depending on the pressing pressure required for the respectivecompression step,

changing the travel path of the compressors 3.1, 3.2, 3.3 depending onat least one of the set values, such as width, height and/or length, aswell as density of the package 20,

increase in weight of the supplied material per unit time (gradient).

For this purpose, a hydraulic system is employed which drives thecompressors 3.1, 3.2, 3.3 and the door 5.1 using the hydraulic drivesystem 9.1, the pistons/cylinders 6.1, 6.2, 6.3, 6.4 and control blocks9.2. The hydraulic system includes

an available maximum pressure,

valves controlled and sized depending on the process steps,

hydraulic circuits separated by a valve in the respective section of thecontrol block 9.2 and adapted for simultaneous processes requiringdifferent oil quantities,

coupling of operations using a fixed predetermined oil transfer,

a monitoring system for identifying leaks in the hydraulic system,

a compact control block 9.2 for the compressor 3.3 disposed above oradjacent to the piston/cylinder 6.3, and

electronic distance measurement devices/sensors which are associatedwith and/or integrated with the pistons/cylinders 6.1, 6.2, 6.3.

A control device processes the signals of the distance measurementdevices for weighing/feeding the material for the purpose of monitoringthe package size/density for a pre-selectable package length and/orpackage density.

Advantageously, a control device with alarm devices is employed whichcan disconnect the control devices which control the compacting steps,when the compressors 3.1 and/or 3.2 fail to reach their respective endpositions. during maintenance/repair, at least one of the compressors3.1, 3.2, 3.3 is moved into a position so that the space required forthe maintenance/repair, in particular for exchanging the wear lining, isaccessible without requiring removal of one of the compressors 3.1, 3.2,3.3.

The method to be implemented requires a combination of featuresaccording to the invention, so that

the shearing edge 4.1 and the edge of the shearing knife 4.2, as viewedfrom the top, form a triangle at the start of the shearing process, thecompressor 3.1 is guided so as not to be subjected to a tilting torqueand has non-adjustable limit stops 7.1 (FIG. 1) which form a guide forattaining the end position in a parallel plane,

the compressor 3.2 is provided with non-adjustable limit stops 7.2 whichform a guide for attaining the end position in a parallel plane, and

the length of the compressor 3.3 is selected so that material fallingdown during the return stroke of the compressor 3.3 cannot enter a space8 surrounding the piston/cylinder 6.1, 6.3 (FIG. 6a), b)).

Moreover, the full available pressure of the hydraulic drive system 9.1can be applied to the compressors 3.1, 3.2, 3.3 during the respectivepressing process, whereas during the simultaneous movement of thecompressors 3.1, 3.2, 3.3, the active pump circuits of the compressors3.1, 3.2, 3.3 are hydraulically separated in the respective controlblock 9.2 from at least one of the compressors 3.1, 3.2, 3.3 and/or thedoor 5.1 through a valve, and the movement of at least one of thecompressors 3.1, 3.2, 3.3 is coupled with that of another compressor3.1, 3.2, 3.3 by a fixed predetermined transfer of oil.

It is important in the newly designed system that the door 5.1 contactsthe housing of the package chamber 2.3 with a tension force determinedby tension rods 10 so as to absorb the pressing force of the compressor3.3, wherein the pressing forces are static forces absorbed between thecompressor 3.3 and the tension rods 10.

For enhancing the synergy of the construction, the door 5.1 is guided bya door casing 5.2 in the form of a closed frame. The tension rods 10oppose each other and extend diagonally on corners along the pressingchamber 2.3, providing additional support for the door casing 5.2 whichis attached to the housing portion of the package chamber 2.2.

Advantageously, the guides 5.3, 5.4 of the door 5.1 are designed to beself-cleaning.

All lubrication bores are arranged in such a way that they cannot beblocked by abraded material.

For improved functionality, the piston/cylinder 6.4 effecting openingand closing of the door 5.1 is disposed in the center of thecross-section of the door 5.1.

In an advantageous space-saving arrangement, the piston/cylinder 6.4 isintegrated next to the compressor (3.1) and the side wall of the housingof the filling chamber 2.1.

To facilitate the filling process, a pressing cover 11 can be providedon the filling chamber 2.1.

A continuous production of pressed parts (20) of approximately equalmass is facilitated by a metering device 12 which can be formed as acontainer scale (FIG. 8a) or a trough-tipping scale (FIG. 8b).

All guides, in particular the guides of the compressors 3.1, 3.2, 3.3and of the door 5.1, are connected with a central, automaticallycontrolled lubrication system 21 through lubrication lines 22 (FIG. 7).

Using a wash-board-type profile for wear part linings enables mechanicalseparation of interfering material of all types and shapes (FIG. 1, FIG.4).

An installation which reduces the required base area and the area forthe foundation, is provided by an arrangement, wherein

the compact hydraulic control block 9.2 is directly associated with theshearing and compacting press 1,

the hydraulic tank 13 and the hydraulic drive system 9.1 and/or thelubrication system for automatic lubrication form a pre-assembledsubassembly 15, which rests on a frame-like oil pan 14, and

a control box 16 is associated with the subassembly 15.

Advantageously, the subassembly 15 is arranged in the angle enclosedbetween the filling chamber 2.1 and the piston/cylinder 6.3 of thecompressor 3.3.

The shearing and compacting press according to the invention, withrespect to both the method of operation and the product, provides for anoperator an increased service value for the following reasons:

automatic continuous or single-event operation, for producing thepressed parts or only a single pressed part,

tamping operation, wherein the compressor 3.1 pushes the materialtogether and then again unblocks the fill opening,

manual operation allowing separate movement of the pistons/cylinders6.1, 6.2, 6.3, with electric interlocking of the sequence of steps, and

a reasonable repair process flow.

The pressing pressure of the compressors 3.1, 3.2, 3.3 can be adjustedin steps, allowing production of pressed parts with optimized highdensity, without requiring unnecessary time and energy to establish thepressing pressure.

Industrial Applicability

The invention as a whole contributes to reduce the investment and thecosts for operating the machine, and in addition shortens the cycletimes of the shearing and compacting press and increases theproductivity and the quality in the production of pressed parts.

What is claimed is:
 1. A method for operating a shearing and compactingpress for producing a pressed package from waste material, comprisingthe steps of: a first compacting step for pre-compacting supply materialto a predetermined width of the pressed part using a first compressorwhich is non-adjustably guided substantially horizontally on asubstantially parallel plane in a filling chamber at a continuouslyapplied force, supply material projecting over the first compressor issheared when the first compressor and a shearing knife disposed thereonare moved towards so as to contact a shearing edge shearing excesssupply material therebetween, the substantially parallel planesubstantially eliminating tilting movement of the first compressorduring shearing until a final position of the first compacting step; asecond compacting step for intermediate compacting the supply materialthat has been pre-compacted to the width of the pressed part to apredetermined height of the pressed part using a second compressornon-adjustably guided along a substantially parallel plane in a pressurechamber in a direction substantially perpendicular to the fillingchamber towards an end position of the second compacting step; a thirdcompacting step for final compacting of the supply material to apredetermined length of the pressed part using a third compressor guidedin a package chamber substantially horizontally and in a directionsubstantially perpendicular to the filling chamber, the first compressorbeing in a position unblocking an opening of the package chamber whenthe third compressor is returned to a position in which falling materialdoes not interfere with stroke movement of the third compressor, whereinthe first, second and third compacting steps are controlled by a drivesystem producing a hydraulic pressure; and ejecting the pressed partthrough the opening of the package chamber; wherein pressure applied tothe respective compressors at the beginning of stroke movement andduring return strokes is below a maximum available pressure, a maximumattainable pressure being applied to at least one of: (i) the firstcompressor during shearing operation and (ii) the second and thirdcompressors at end positions of the respective pressing operations; andautomatically controlling the pressing pressure for the compressorsbased on a degree of compression and the respective length of thepressed package so as to control the compression process until the thirdcompacting step is completed.
 2. The method according to claim 1,wherein the return strokes of the first and third compressors arecoupled, wherein the third compressor travels an initial portion of adisplacement path by itself and a remaining portion of the path togetherwith the first compressor.
 3. The method according to claim 2, whereinthe movements of the first and third compressors are matched to oneanother so that the first compressor is returned behind the shearingedge to permit material to be fed again into the filling chamber onlyafter the third compressor on the return stroke in the package chamberis in a region which prevents material from entering a space behind thethird compressor.
 4. The method according to claim 3, wherein theopening of the package chamber is closed off by a door, the door beingclosed simultaneously with the return stroke of the third compressor viahydraulic separation.
 5. The method according to claim 4, wherein anopening of the package chamber is closed off by a door, the door beingopened simultaneously with the return stroke of the second compressorvia hydraulic separation.
 6. The method according to claim 5, furthercomprising a piston/cylinder associated with each compressor; and ameasurement system for monitoring movements of the compressors, movementof the door and the pressed package size; the measurement systemsupplies signals for changing at least one of material feed, packagedensity, pressure applied to the pistons/cylinders and oil levelleakage.
 7. The method according to claim 6, further comprising acontrol device for driving the compressors and the door, the controldevice during the first, second and third compacting steps and ejectionof the package is recording and processing at least one of the followingfunctions before the supply material is supplied: a) changing thematerial supply depending on the material required for the compactingprocess, b) changing the pressing pressure of at least one of thecompressors depending on the pressing pressure required for therespective compression step, c) changing the travel path of thecompressors depending on at least one of width, height, length anddensity of the pressed package, d) increasing in weight of the supplymaterial per unit time.
 8. The method according to claim 7, furthercomprising a hydraulic system for driving the compressors and the door,using a hydraulic drive system, the pistons/cylinders and controlblocks, wherein the hydraulic system comprises: a) an available maximumpressure, b) valves controlled and sized depending on the process steps,c) hydraulic circuits separated by a valve in a respective section ofthe control block and adapted for simultaneous processes requiringdifferent oil quantities, d) coupling of operations using a fixedpredetermined oil transfer, e) a monitoring system for identifying leaksin the hydraulic system, f) the control block controls the thirdcompressor and is disposed above or proximate to the piston/cylinderassociated with the third compressor, and g) electronic distancemeasurement devices/sensors which are associated with and/or integratedwith the respective pistons/cylinders.
 9. The method according to claim8, further comprising a control device that processes signals receivedfrom distance measurement devices for weighing/feeding the supplymaterial so as to monitor the pressed package size/density for apre-selectable package length and/or package density.
 10. The methodaccording to claim 9, wherein the control device includes an alarmdevice for disconnecting the control devices that control the compactingsteps, when at least one of the first and third compressors fail toreach their respective end positions during the respective compactingoperation.
 11. The method according to claim 10, further comprising thestep, during maintenance/repair, moving at least one of the compressorsinto a position so that a space required for exchanging of a wearlining, is accessible without removal of one of the compressors.
 12. Ashearing and compacting press, comprising: a filling chamber having ashearing edge; a first compressor including a shearing knife, the firstcompressor being guided horizontally in the filling chamber, wherein ata start of the shearing process when viewed from the top, the shearingedge and edge of the shearing knife form a triangle; a pressing chamberarranged substantially perpendicular to the filling chamber; a secondcompressor guided in the pressing chamber along a substantially parallelplane, the second compressor having limit stops as a guide for reachingan end compacting position; a package chamber oriented horizontally andsubstantially perpendicular to the filling chamber; the package chamberhaving an opening through which a pressed package is ejectedtherethough; the filling chamber and the pressing chamber terminating ina common space of the package chamber that receives the pressed package;walls of the filling chamber, the pressing chamber and the packagechamber forming a housing of the shearing and compacting press; a thirdcompressor substantially horizontally guided in the package chamber, alength of the third compressor being selected so that during returnstroke, falling material is prevented from entering a space surroundingthe pistons/cylinders associated with the first and third compressors,wherein pressure applied to the respective compressors at the beginningof stroke movement and during return strokes is below a maximumavailable pressure, a maximum attainable pressure being applied to atleast one of: (i) the first compressor during shearing operation and(ii) the second and third compressors at end positions of the respectivepressing operations; a door moveable in a substantially horizontaldirection to close off the opening of the package chamber; eachcompressor and the door having an associated piston/cylinder fordisplacement of the respective compressor; and a hydraulic drive systemconnected so as to displace the compressors and door via the associatedpistons/cylinders.
 13. The shearing and compacting press according toclaim 12, wherein during simultaneous movement of the compressors,active pump circuits of the compressors are hydraulically separated in arespective control block from at least one of the door and at least oneof the compressors by a valve, movement of one of the compressors iscoupled with that of another compressor by a fixed predeterminedtransfer of oil.
 14. The shearing and compacting press according toclaim 13, wherein the door includes tension rods defining tension of thedoor on the package chamber and absorbing static pressure forces betweenthe third compressor and the tension rod.
 15. The shearing andcompacting press according to claim 14, wherein the door is guided by aclosed frame door casing having guides, the tension rods oppose eachother and extend diagonally on comers along the package chamberproviding additional support for the door casing attached to a housingof the package chamber.
 16. The shearing and compacting press accordingto claim 14, wherein the guides are self-cleaning.
 17. The shearing andcompacting press according to claim 16, wherein lubrication bores arearranged so as not to be blocked by abraded material.
 18. The shearingand compacting press according to claim 14, wherein the piston/cylindereffecting opening and closing of the door is disposed substantiallycentered of the cross-section of the door.
 19. The shearing andcompacting press according to claim 18, wherein the piston/cylindereffecting opening and closing of the door is arranged integrated withthe first compressor and a side wall of a housing of the fillingchamber.
 20. The shearing and compacting press according to claim 18,further comprising a pressing cover provided on the filling chamber. 21.The shearing and compacting press according to claim 20, furthercomprising a metering device arranged before the filing chamber forcontinuously producing pressed packages of approximately equal mass. 22.The shearing and compacting press according to claim 21, each compactorhaving a guide, further comprising a central automatically controlledlubrication system for connecting the guides of the compressors and ofthe door via lubrication lines.
 23. The shearing and compacting pressaccording to claim 12, wherein the compressors have a wash-board-typeprofile wear part lining for separating out interfering material of alltypes and shapes.
 24. The shearing and compacting press according toclaim 12, further comprising: a control block directly associated withthe shearing and compacting press; a pre-assembled subassemblycomprising a hydraulic tank and at least one of the hydraulic system anda lubrication system for automatic lubrication, the pre-assembledsubassembly resting on an oil pan; and a switch box associated with thesubassembly.
 25. The shearing and compacting press according to claim24, wherein the subassembly is arranged in an angle defined between thefilling chamber and the piston/cylinder associated with the thirdcompressor.